Sealant assemblies and methods

ABSTRACT

Sealant assemblies and methods are provided for sealing an interface between a surface and a projection extending from the surface. The sealant assembly includes a body portion circumscribing an area to form a sealant pocket and a filling sealant at least partially filling the sealant pocket. The filling sealant and the body portion comprise substantially the same material.

FIELD OF THE INVENTION

The present invention relates to sealant assemblies and methods, andmore particularly, to sealant assemblies and methods adapted to seal aninterface between a surface and a projection extending from the surface.

BACKGROUND OF THE INVENTION

Buildings commonly incorporate roof surfaces designed to repel water andprevent water from leaking into interior areas of the building.Frequently, roof surfaces are also designed to accommodate one or moreroof projections extending from the roof surface. For example, it isknown to penetrate a roof surface with an exhaust pipe to allow ventingof gases generated within the building. When roof projections arenecessary, special care must be taken to avoid leak paths at theinterface between the roof surface and the roof projection.

In an effort to prevent leaks, it is known to treat the interface areabetween the exhaust pipe and the roof surface with a sealant assembly.Conventional sealant assemblies are typically formed by circumscribingthe exhaust pipe with a body portion to create a roof pocket about theexhaust pipe. Once the roof pocket is formed, a filling sealant isintroduced into the roof pocket to complete the sealant assembly.

While frequently useful in various applications, conventional sealantassemblies may fail due to environmental exposure. For example,conventional sealant assemblies include a body portion and a fillingsealant that comprise different materials having substantially differentcoefficients of expansion. The differing coefficients of expansion canresult in fracture of the interface between the body portion and thefilling sealant as components of the assembly expand and contract atdifferent rates during heating and cooling cycles. Moreover, forming thebody portion and the filling sealant from different materials maydiscourage or prevent integral bonding that may further contribute tofailure of any attachment interface between the body portion and thefilling sealant.

For the reasons set forth above, conventional sealant assemblies mayeventually degrade such that the body portion and the filling sealantare disassociated from one another. Such disassociation can contributeto leak-path formation that can lead to unnecessary and potentiallycatastrophic water damage within the building. Disassociation of thebody portion can also introduce a loose object on the roof surface thatmight introduce a tripping hazard. A disassociated body portion may alsotumble from the roof and thereafter present a dangerous falling object.

SUMMARY OF THE INVENTION

Accordingly, it is an aspect of the present invention to obviateproblems and shortcomings of conventional sealant assemblies andmethods. More particularly, it is an aspect of the present invention toprovide sealant assemblies and methods that discourage disassociationbetween the body portion and the filling sealant of the sealantassembly.

In accordance with one aspect, a sealant assembly is provided forsealing an interface between a surface and a projection extending fromthe surface. The sealant assembly includes a body portion circumscribingan area to form a sealant pocket. The sealant assembly further includesa filling sealant at least partially filling the sealant pocket. Thefilling sealant and the body portion comprise substantially the samematerial.

In accordance with another aspect, a method of sealing an interfacebetween a surface and a projection extending from the surface isprovided. The method includes the step of positioning a body portion onthe surface with the body portion circumscribing the projection and theprojection extending through a sealant pocket defined by the bodyportion and the surface. The method further includes the step of addinga filling sealant into the sealant pocket, wherein the filling sealantsubsequently solidifies such that the body portion and the solidifiedfilling sealant form a solid sealant assembly with the body portion andthe solidified filling sealant comprising substantially the samematerial.

In accordance with still another aspect, a sealant assembly is provided.The sealing assembly includes a body portion circumscribing an area toform a sealant pocket and a solidified filling sealant within the areaand filling at least a portion of the sealant pocket. The sealantassembly is formed by a process including the step of positioning thebody portion on a surface with the body portion circumscribing aprojection extending from the surface. The process further includes thestep of adding a filling sealant into the sealant pocket, wherein thefilling sealant is substantially contained within the sealant pocket.Still further, the process includes the step of permitting the fillingsealant to solidify such that the body portion and the solidifiedfilling sealant form a solid sealant assembly with the body portion andthe solidified filling sealant comprising substantially the samematerial.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the present inventionwill become apparent to those skilled in the art to which the presentinvention relates upon reading the following description with referenceto the accompanying drawings, in which:

FIG. 1A is a perspective view demonstrating an exemplary step ofassembling a body portion to circumscribe a projection extending fromthe surface;

FIG. 1B is a perspective view of an assembled body portion;

FIG. 1C is a perspective view demonstrating an exemplary step of addinga filling sealant into a sealant pocket;

FIG. 1D is a perspective view of an exemplary sealant assembly inaccordance with aspects of the present invention;

FIG. 2 is a sectional view of the sealant assembly taken at line 2-2 ofFIG. 1D;

FIG. 3 is a top plan view of an exemplary corner element in accordancewith aspects of the present invention;

FIG. 4A is a sectional view of the corner element along line 4A-4A ofFIG. 3;

FIG. 4B is a sectional view of the corner element along line 4B-4B ofFIG. 3

FIG. 5 is a left side elevational view of the corner element of FIG. 3;

FIG. 6 is a front elevational view of the corner element of FIG. 3;

FIG. 7 is an assembled body portion in accordance with another exemplaryembodiment of the present invention;

FIG. 8 is a sectional view of the body portion along line 8-8 of FIG. 7;and

FIG. 9 is another embodiment of a corner element in accordance withaspects of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Certain terminology is used herein for convenience only and is not to betaken as a limitation on the present invention. Further, in thedrawings, the same reference numerals are employed for designating thesame elements, and in order to clearly and concisely illustrate thepresent invention, certain features may be shown in somewhat schematicform.

FIGS. 1A-1D illustrate an exemplary method of providing a sealantassembly 20 adapted to seal an interface 204 between a surface 200 andone or more projections 202 extending from the surface 200. Sealantassemblies and methods herein may be applied in a wide range ofapplications. For instance, sealant assemblies may be used inapplications where it is necessary to provide a fluid seal at aninterface between a projection and a surface. In one example, thesealant assembly can be used to seal an interface between a roof surfaceand a vent pipe extending from the roof surface.

Sealant assemblies herein include a body portion that may circumscribe asingle projection or any plurality of projections in accordance withaspects of the present invention. Body portions may be provided in awide variety of shapes and/or sizes depending on the particularapplication. Moreover, the body portion may be provided as a singlepiece or might be provided as a plurality of pieces that can beassembled together to circumscribe the one or more projections. Forinstance, the body portion might comprise a continuous ring in a varietyof shapes such as a continuous circular, oval, square, triangular,rectangular, or other continuous shape that can circumscribe aprojection. The continuous ring can be placed over the top of theprojection to circumscribe the projection adjacent the interface. Infurther embodiments, the ring may be split so that it is not necessaryto place the ring over the top of the projection. For example, the ringmay be split at a single location wherein the projection may belaterally inserted through the slit to enter the interior area of thering. In another example, the ring may be split at two locations,wherein the ring halves may be closed around the projection tocircumscribe the projection.

In still further examples, the body portion might comprise a pluralityof corner elements adapted to at least partially circumscribe theprojection. For example, as shown in FIGS. 1A-1D, a body portion 30includes a plurality of corner elements 40 that are arranged to at leastpartially circumscribe the one or more projections 202. One exemplarycorner element 40 is illustrated in FIGS. 3-6. As shown in FIG. 3, thecorner element 40 can include a first extension arm 42 extending along afirst extension axis 42 a and a second extension arm 44 extending alonga second extension axis 44 a. As shown, the first extension axis 42 aand second extension axis 44 a are substantially perpendicular withrespect to one another. It is also contemplated that the first andsecond extension axis may be located at different angular orientationsdepending on the shape of the body portion. For example, the first andsecond extension axis might be located at an angle of 60 degrees fromone another to form a triangular body portion having three cornerelements.

The illustrated corner element is shown to include relatively sharpcorners. In further embodiments, the corner elements may compriserounded corners to reduce stress points. For example, the corner elementcan comprise a first and second extension arm together with a roundedcorner portion positioned between the first and second extension arm. Infurther embodiments, the entire corner element may comprise a roundedcorner portion.

As shown in the illustrated embodiment, the extension arms 42, 44comprise the same length. It is contemplated that the extension arms, ifprovided, may be longer or shorter than the relative length illustratedin the figures. Moreover, it is contemplated that the extension armsmight comprise different lengths in further embodiments.

In accordance with exemplary embodiments of the present invention, thefirst extension arm 42 can include a first end portion 46 a with a firstsubstantially flat surface 48 a that is substantially perpendicular tothe first extension axis 42 a. Similarly, the second extension arm 44can include a second end portion 46 b with a second substantially flatsurface 48 b that is substantially perpendicular to the second extensionaxis 44 a. Providing the end portions with a substantially flat surfacethat is substantially perpendicular to the respective extension axis canfacilitate connection of body portion elements. For example, endportions with perpendicular surfaces can allow compression of the endportions without significant development of shear stress and withoutdeforming the end portions away from the extension axis. In contrast,compression of diagonal surfaces can develop significant shear stressesand might wedge against each other to deform the end portions away fromthe extension axis and therefore interfere with the fastening process.

In further examples, end portions of body components may havealternative configurations to facilitate connection of the components toone another. For example, FIG. 9 depicts a corner element 140 includinga first end portion 146 a with a tongue 142 and a second end portion 146b with a groove 144. When fastening a plurality of corner elementstogether, the tongue 142 of one corner element may be inserted within agroove 144 of another corner element to link the corner elements to oneanother. Providing a tongue and groove arrangement can facilitatefastening the end portions together and can increase the overallstrength of the subsequently formed joint.

As shown in FIGS. 4A, 4B, 5 and 6 each corner element can include asubstantially flat base 42 b, 44 b adapted to rest on a substantiallyflat surface 200. The corner elements further include boundary surfaces42 c, 44 c adapted to at least partially define a perimeter boundary ofthe interior area 32 of the body portion 30. The corner elements furtherinclude an outer surface 42 d, 44 d extending between the correspondingflat bases 42 b, 44 b and boundary surfaces 42 c, 44 c. As shown inFIGS. 4A and 4B, the outer surface, boundary surface, and flat base canform a triangular configuration although other configurations may beemployed in accordance with aspects of the present invention.

FIG. 7 is an assembled body portion 130 in accordance with anotherembodiment of the present invention. The body portion 130 includes atleast a pair of intermediate segments 50 a, 50 b. The intermediatesegments, if provided, can extend at least one dimension of the bodyportion to create an enlarged sealant pocket 134. In the illustratedembodiment, a second pair of intermediate segments 52 a, 52 b is alsoprovided to extend a second dimension of the body portion to furtherenlarge the sealant pocket 134.

The intermediate segments, if provided, can include a wide variety ofsizes to customize the size of the sealant pocket. For example, thefirst pair of intermediate segments 50 a, 50 b may have a first lengthand the second pair of intermediate segments 52 a, 52 b may have asecond length. The first and second lengths may be equal or differentfrom one another depending on the desired size of the body portion. Forexample, the intermediate segments 50 a, 50 b, 52 a, 52 b can havesubstantially identical lengths to form a substantially square shapedbody portion. In further examples, the first pair of intermediatesegments 50 a, 50 b may have a different length than the second pair ofsegments 52 a, 52 b to form a substantially rectangular shaped pitchpocket. In still further examples, only one pair of segments is used toextend the length of the pitch pocket in a single desired direction. Infurther examples, the body portion may be provided as a kit with fourrelatively long intermediate segments. The relatively long intermediatesegments may be cut on site to provide a customized body portion havingan appropriate size. Customizing the body portion can reduce the overallsize of the body portion wherein less filling sealant is necessary tofill the sealant pocket.

The intermediate segments may also have various shapes in accordancewith aspects of the present invention. As shown in FIG. 8, for example,the intermediate segment may have a triangular configuration thatmatches the configuration of the corner elements. In further examples,the intermediate segments can include a substantially flat surface 56that is substantially perpendicular to the extension axis of theintermediate segment. Providing a perpendicular flat surface 56 canfacilitate fastening of the intermediate segments between opposed cornerelements. The intermediate segments can also extend along asubstantially straight axis but might extend along a substantiallycurved axis in further applications.

An exemplary method of sealing an interface between a surface and aprojection extending from the surface is described with respect to FIGS.1A-1D but can apply equally to exemplary embodiments describedthroughout this application. First, the body portion 30 is positioned onthe surface 200 with the body portion 30 circumscribing the projections202. In the illustrated embodiment, the corner elements 40 aresufficient to circumscribe each of the projections 202. Double-sidedtape 49 or other adhesive may be used to fasten together the flat endsurfaces to maintain the desired shape of the assembled sealant pocket.Once fastened together, the complete body portion 30 is formed as shownin FIG. 1B. The boundary surfaces 42 c, 44 c of each extension arm ofthe completed body portion cooperate to form a peripheral boundarydefining the interior area 32. Once the assembled body portion 30 isplaced against the surface 200, the boundary surfaces 42 c, 44 c of eachextension arm cooperate with the surface 200 adjacent the interior area32 to form a sealant pocket 34. As shown, the sealant pocket 34 isformed with the projections 202 extending through the sealant pocket 34.

The body portion 30 may also be sealed or fastened with respect to thesurface 200. Providing a seal between the body portion 30 and thesurface 200 may help contain filling material within the sealant pocketas the filling material solidifies. Fastening the body portion 30 to thesurface 200 can also help maintain the sealant pocket 34 in the desiredlocation with respect to the one or more projections 202. In theillustrated example, tape 36, such as a Butyl tape, can be used to forma seal the body portion 30 to the surface 200 and/or can help fasten thebody portion 30 with respect to the surface 200. In further examples, anadhesive layer or other sealant layer may be used to aid in sealingand/or fastening of the body portion.

As shown in FIG. 1C, filling sealant 60 may then be added into thesealant pocket 34. In the illustrated embodiment, filling sealant 60 isadded by pouring the filling sealant 60 into the sealant pocket with abucket 70. In further examples, the filling sealant 60 may be introducedwith a hose or other container. Still further, the filling sealant maybe added without pouring. For example, filling sealant may be scoopedinto the cavity, shoveled into the cavity, packed into the cavity, orotherwise introduced into the cavity. The filling sealant 60 maycomprise a premixed sealant material or may comprise material ofsegregated components that are mixed just prior to adding the sealant tothe pocket. Mixing just prior to adding the sealant can be conducted ina variety of ways. For example, two or more sealant components may bemixed in a container using a mixing paddle, stirring blade, or manuallyusing a spatula or the like. In further examples, two or more sealantcomponents may be segregated in a cartridge and mixed just prior toadding the filling sealant to the sealant pocket. In one example, acartridge may be provided with segregated sealant reservoirs that are incommunication with a static mixing tip. When dispensing the componentsfrom the cartridge, the static mixing tip causes the components to mixas the filling sealant is added to the cavity. Sufficient fillingsealant can be added until the level of filling sealant extends to afill line 61 relative to the projections 202. The fill line 61 may bepredetermined or may simply comprise the final level that the fillingsealant 60 reaches with respect to the projections 202. The fill line 61may be less than, equal to, or greater than the height of the bodyportion 30. Providing a fill line 61 that is less than the height of thebody portion 30 can reduce the overall amount of filling sealant 60necessary to complete the sealant assembly. Providing a fill line 61that is equal to the height of the body portion 30 (as shown in FIG.1D), or greater than the height of the body portion can avoid trappingwater within unfilled portions of the sealant pocket.

As shown in FIG. 2, providing the body portion and the solidifiedfilling sealant as the same material can cause the filling sealant 60 tobe integrally bonded to the body portion 30 at an interface 47 betweenthe filling sealant and the body portion. Integral bonding can occur asouter layers of the boundary surfaces of the body portion 30 soften andblend with the filling sealant that is added into the sealant pocket.After a sufficient period of time, the filling sealant and softened andblended portions solidify wherein the filling sealant 60 is integrallybonded with the body portion 30 at the interface 47.

Accordingly, the corner elements, intermediate segments (if provided),and the filling material comprise substantially the same material toform a solid, sealed block around the roof protrusions 202. Being formedfrom the same material, the assembled body portion and the fillingmaterial have the same coefficient of expansion and therefore resistcracks or other failures that may otherwise occur due to temperaturefluctuations. Still further, forming the assembled body portion and thefilling material from substantially the same material can facilitateintegral bonding at the interface between the body portion and thefilling sealant to further resist cracks or other failures of theconnection between the body portion and the filling sealant.

A wide range of materials may be used as the common material to form thecorner elements, intermediate elements (if provided), and the fillingmaterial. For example, the common material can comprise a wide varietyof polymers, such as polymers and copolymers EPDM, Butyl rubber,Neoprene, SSBS, SEBS, Hypalon, Acrylic elastomers, CPE, PVC, CPVC,epichlorohydrin, ethylene acrylic elastomers, EPR, PIB, polybutadienerubbers, polynorbomenes, polysulfide, one and two part urethaneelastomers, and the like. Other materials may be used as the commonmaterial to provide a sealant assembly with components having the samecoefficient of expansion or components that form an integral bond withthe filling material.

From the above description of the invention, those skilled in the artwill perceive improvements, changes and modifications. Suchimprovements, changes and modifications within the skill of the art areintended to be covered by the appended claims.

1. A sealant assembly for sealing an interface between a surface and aprojection extending from the surface, the sealant assembly comprising:a body portion circumscribing an area to form a sealant pocket; and afilling sealant at least partially filling the sealant pocket, whereinthe filling sealant and the body portion comprise substantially the samematerial.
 2. The sealant assembly of claim 1, wherein the body portioncomprises a plurality of corner elements adapted to at least partiallycircumscribe the area to form the sealant pocket.
 3. The sealantassembly of claim 2, wherein each corner element includes a firstextension arm with a first end portion including a tongue and a secondextension arm with a second end portion including a groove.
 4. Thesealant assembly of claim 2, wherein each corner element includes afirst extension arm extending along a first extension axis, the firstextension arm including a first end portion with a first substantiallyflat surface that is substantially perpendicular to the first extensionaxis; and a second extension arm extending along a second extensionaxis, the second extension arm including a second end portion with asecond substantially flat surface that is substantially perpendicular tothe second extension axis.
 5. The sealant assembly of claim 2, whereinthe body portion further comprises at least a pair of intermediatesegments, wherein the corner elements and the intermediate segments atleast partially circumscribe the area to form the sealant pocket.
 6. Thesealant assembly of claim 1, wherein the same material comprises apolymer material.
 7. The sealant assembly of claim 6, wherein thepolymer material comprises a polyurethane material.
 8. The sealantassembly of claim 6, wherein the polymer material comprises a polyureamaterial.
 9. The sealant assembly of claim 1, wherein the fillingsealant is integrally bonded to the body portion at an interface betweenthe filling sealant and the body portion.
 10. A method of sealing aninterface between a surface and a projection extending from the surfacecomprising the steps of: positioning a body portion on the surface withthe body portion circumscribing the projection and the projectionextending through a sealant pocket defined by the body portion and thesurface; and adding a filling sealant into the sealant pocket, whereinthe filling sealant subsequently solidifies such that the body portionand the solidified filling sealant form a solid sealant assembly withthe body portion and the solidified filling sealant comprisingsubstantially the same material.
 11. The method of claim 10, furthercomprising the step of providing the body portion with a plurality ofcorner elements and wherein the step of positioning the body portioncomprises positioning the plurality of corner elements to at leastpartially circumscribe the projection.
 12. The method of claim 10,further comprising the step of providing the body portion with aplurality of corner elements that each include a first extension armwith a first end portion including a tongue and a second extension armwith a second end portion including a groove, wherein the step ofpositioning the body portion comprises positioning the tongue of eachcorner element within the groove of another corner element.
 13. Themethod of claim 10, further comprising the step of providing the bodyportion with a plurality of corner elements that each include a firstextension arm extending along a first extension axis, the firstextension arm including a first end portion with a first substantiallyflat surface that is substantially perpendicular to the first extensionaxis and a second extension arm extending along a second extension axis,the second extension arm including a second end portion with a secondsubstantially flat surface that is substantially perpendicular to thesecond extension axis, wherein the step of positioning the body portioncomprises attaching the first substantially flat surface of each cornerelement with the second substantially flat surface of another cornerelement.
 14. The method of claim 10, further comprising the step ofproviding the body portion with a plurality of corner elements and atleast a pair of intermediate segments, wherein the step of positioningthe body portion comprises positioning the corner elements and theintermediate segments to at least partially circumscribe the area toform the sealant pocket.
 15. The method of claim 10, wherein the samematerial comprises a polymer material.
 16. The method of claim 10,wherein the step of adding a filling sealant into the sealant pocketresults in an integral bond of the filling sealant to the body portionat an interface between the filling sealant and the body portion.
 17. Asealant assembly comprising a body portion circumscribing an area toform a sealant pocket and a solidified filling sealant within the areaand filling at least a portion of the sealant pocket, the sealantassembly formed by a process including the steps of: positioning thebody portion on a surface with the body portion circumscribing aprojection extending from the surface; adding a filling sealant into thesealant pocket, wherein the filling sealant is substantially containedwithin the sealant pocket; and permitting the filling sealant tosolidify such that the body portion and the solidified filling sealantform a solid sealant assembly with the body portion and the solidifiedfilling sealant comprising substantially the same material.
 18. Themethod of claim 17, further comprising the step of providing the bodyportion with a plurality of corner elements and wherein the step ofpositioning the body portion comprises positioning the plurality ofcorner elements to at least partially circumscribe the projection. 19.The method of claim 17, further comprising the step of providing thebody portion with a plurality of corner elements that each include afirst extension arm extending along a first extension axis, the firstextension arm including a first end portion with a first substantiallyflat surface that is substantially perpendicular to the first extensionaxis and a second extension arm extending along a second extension axis,the second extension arm including a second end portion with a secondsubstantially flat surface that is substantially perpendicular to thesecond extension axis, wherein the step of positioning the body portioncomprises attaching the first substantially flat surface of each cornerelement with the second substantially flat surface of another cornerelement.
 20. The method of claim 17, further comprising the step ofproviding the body portion with a plurality of corner elements and atleast a pair of intermediate segments, wherein the step of positioningthe body portion comprises positioning the corner elements and theintermediate segments to at least partially circumscribe the area toform the sealant pocket.
 21. The method of claim 17, wherein the samematerial comprises a polymer material.
 22. The method of claim 17,wherein the step of adding a filling sealant into the sealant pocketresults in an integral bond of the filling sealant to the body portionat an interface between the filling sealant and the body portion.